Label stacking machine and method

ABSTRACT

A method of making a pad of labels comprises: printing display information on a top surface of a substrate; affixing a first layer of lamination material to a bottom surface of the substrate; affixing a second layer of lamination material to the top surface of the substrate, the second layer of lamination material having a release coating applied to a top surface thereof; applying an adhesive strip to a bottom surface of the first layer of lamination material, the adhesive strip being covered by a liner material; cutting the substrate having first and second layers of lamination material affixed into at least one label; removing the liner material to expose the adhesive strip after cutting the substrate into at least one label; and arranging the labels into a pad of labels.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.16/045,225 filed on Jul. 25, 2018, which is a continuation of U.S.patent application Ser. No. 15/131,202 (now U.S. Pat. No. 10,059,090),filed on Apr. 18, 2016, which is a continuation of U.S. patentapplication Ser. No. 14/843,337 (now U.S. Pat. No. 9,376,286), filed onSep. 2, 2015, which claims the benefit of U.S. Provisional PatentApplication No. 62/044,598 filed Sep. 2, 2014 entitled “Robotic MeansUsed in the Process of Making a Sheet of Labels”, each of which isincorporated by reference herein in its entirety.

BACKGROUND OF THE INVENTION

The present invention generally relates to machines and methods forstacking a plurality of labels. In some embodiments, the presentinvention relates to machines and methods for stacking sheets of labelsinto pads of labels for use on store shelves in a retail environment.

BRIEF SUMMARY OF THE INVENTION

In one embodiment there is a method of making a pad of labelscomprising: providing a substrate having printed display material on atop surface of the substrate, a first layer of lamination material on abottom surface of the substrate, a second layer of lamination materialhaving a release coating on the top surface of the substrate, and anadhesive strip on the bottom surface of the substrate, the adhesivestrip being covered by a liner material; cutting the substrate into atleast one label; removing the liner material to expose the adhesivestrip after cutting the substrate into at least one label; and arrangingthe at least one label into a pad of labels. In one embodiment, the atleast one label include a sheet of labels, and the cutting step includescutting through the substrate and the first and second layer oflamination material around an entire outer perimeter of a plurality ofpartially connected labels. In one embodiment, the cutting step includescutting through the substrate along a majority of a boundary betweenadjacent labels leaving one or more ties to partially connect adjacentlabels. In one embodiment, the cutting step includes partially cuttingthe at least one label proximate the adhesive strip such that the linermaterial is at least partially intact across the sheet of labels.

In a further embodiment, the method of making a pad of labels comprisespulling the at least partially intact liner downwardly from the at leastone labels and winding the at least partially intact liner onto a spool.In a further embodiment, the method of making a pad of labels comprisespulling a trim surrounding the entire outer perimeter of the pluralityof partially connected labels upwardly from the plurality of partiallyconnected labels and winding the trim onto a spool. In one embodiment,the cutting step is performed using a rotary die. In one embodiment, therotary die includes a plurality of cutting edges, at least one of theplurality of cutting edges extending radially further from the rotarydie than another one of the plurality of cutting edges. In a furtherembodiment, the method of making a pad of labels comprises transportingthe at least one label to a stacking station using a transfer conveyorhaving non-stick coated rollers. In one embodiment, transporting the atleast one label includes using a robot arm having a vacuum pick-head tolift the at least one label and place the at least one label onto thetop of the pad of labels. In one embodiment, the printing, cutting, andarranging steps are controlled with reference to a store's planogram,such that the pad of labels is sequenced according to the store'splanogram. In a further embodiment, the method of making a pad of labelscomprises printing the display information on the top surface of thesubstrate; affixing the first layer of lamination material to the bottomsurface of the substrate; affixing the second layer of laminationmaterial to the top surface of the substrate; and applying the adhesivestrip to the bottom surface of the first layer of lamination material.

In another embodiment there is a method of making a pad of labelscomprising: providing a substrate having printed display material on atop surface of the substrate, a first layer of lamination material on abottom surface of the substrate, a second layer of lamination materialhaving a release coating on the top surface of the substrate, and anadhesive strip on the bottom surface of the substrate, the adhesivestrip being covered by a liner material; cutting the substrate havingfirst and second layers of lamination material affixed into at least onelabel; removing the liner material to expose the adhesive strip;transporting the at least one label to a stacking station; lifting theat least one label from the stacking station by applying a vacuum forceto a top surface of the at least one label; moving the at least onelabel over a stack of labels; and releasing the vacuum force to the topsurface of the at least one label to arrange the at least one label intoa pad of labels.

In one embodiment, transporting the at least one label includes using atransfer conveyor having non-stick coated rollers. In a furtherembodiment, the method of making a pad of labels comprises blowing aironto the at least one label during transporting of the at least onelabel to the stacking station. In one embodiment, the stacking stationincludes at least one recess that aligns with the adhesive strip toprevent the adhesive strip from contacting the stacking station. In oneembodiment, the vacuum force is applied using a robot arm, the robot armincluding a pick-head having a foam pad. In one embodiment, the foam padincludes a plurality of apertures.

In another embodiment, there is a device for stacking a plurality ofpartially connected labels into a plurality of partially connected padsof labels, comprising: a robot arm having at least one vacuum sourceconfigured to selectively supply a vacuum force; a plate coupled to therobot arm; and a flexible pad coupled to the plate and including aplurality of apertures configured to direct the majority of the vacuumforce through the flexible pad to a surface of the plurality ofpartially connected labels. In one embodiment, the flexible pad includesa layer of closed cell foam and a layer of open cell foam. In oneembodiment, the apertures are approximately 5 mm in diameter. In oneembodiment, the vacuum force is approximately 10 psi.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

The foregoing summary, as well as the following detailed description ofembodiments of the label stacking machine and method, will be betterunderstood when read in conjunction with the appended drawings of anexemplary embodiment. It should be understood, however, that theinvention is not limited to the precise arrangements andinstrumentalities shown.

In the drawings:

FIG. 1 is a perspective view of a pad of labels having displayinformation printed on a top surface of the labels in accordance with anexemplary embodiment of the present invention;

FIG. 2 is a cross-sectional and exploded view of one of the labels shownin FIG. 1;

FIG. 3 is a perspective view of a plurality of pads of labels on asupport surface in accordance with an exemplary embodiment of thepresent invention with the display information removed;

FIG. 4 is a perspective view of the plurality of pads of labels of FIG.3 shown with one of the pads detached from the support surface;

FIG. 5 is a perspective view of a label assembly and stacking machine inaccordance with an exemplary embodiment of the present invention;

FIG. 6 is a perspective view of the feeding station of the labelassembly and stacking machine shown in FIG. 5;

FIG. 7 is a perspective view of the lamination station of the labelassembly and stacking machine shown in FIG. 5;

FIG. 8 is perspective view of the die cutting station of the labelassembly and stacking machine shown in FIG. 5;

FIG. 9A is a perspective view of a die from the die cutting station ofFIG. 8 shown with the foam coating removed;

FIG. 9B is a side view of the die shown in FIG. 9A;

FIG. 9C is an enlarged view of area 9C shown in FIG. 9A;

FIG. 10 is a schematic layout drawing of the die blades for the diestation shown in FIG. 8;

FIG. 11 is a perspective view of a first unwinding station of the labelstacking machine shown in FIG. 5;

FIG. 12 is a perspective view of a second unwinding station of the labelstacking machine shown in FIG. 5;

FIG. 13 is a perspective view of a conveyor station of the labelstacking machine shown in FIG. 5;

FIG. 14 is a perspective view of a stacking station of the labelstacking machine shown in FIG. 5; and

FIG. 15 is a bottom perspective view of the pick-head plate of robot armin the stacking station shown in FIG. 14.

DETAILED DESCRIPTION OF THE INVENTION

Described herein are embodiments of a machine and method for stacking aplurality of labels into a pad of labels. In some embodiments, themachine and/or method relates to stacking a sheet of labels into aplurality of pads of labels that are partially connected to one another.In some embodiments, the labels are for use on store shelves in a retailenvironment. In particular embodiments, the pads of labels arepreprinted and sequenced according to a retail store's planogram. Thepads of labels may allow for a system of labels that does not require:(1) breaking down a sheet of labels by tearing along label-removalperforations; (2) sorting individual labels; and (3) containerizing orbundling the individual labels. Furthermore, because the labels may bepeeled directly from a pad of peel-and-stick labels, there is noseparate release liner utilized that must be removed from eachindividual label and discarded during use.

An embodiment of the present invention includes a label 10 as depictedin FIGS. 1-3. Specifically, FIG. 1 shows a pad of a plurality ofvertically stacked labels 12 (herein referred to as pad or pad oflabels) having display information 14 printed so as to be visible on thetop surface of the label 10. The display information 14 may include,without limitation, product information, descriptions, marketingcontent, store and shelf location, pricing, discounts and promotions,UPCs and bar codes, and/or effective dates. In some embodiments, thelabel 10 is approximately 2.5 inches wide and approximately 3.5 incheslong. In one embodiment, the label 10 is approximately 1.625 toapproximately 2.625 inches wide and approximately 1.219 to approximately4.0 inches long. Each pad 12 may include any number of labels. In someembodiments, each pad 12 includes approximately 10-150 labels.

FIG. 2 shows a cross-sectional view of a label 10 according to anexemplary embodiment. The label 10 may include a paper substrate 16. Inone embodiment, paper substrate 16 is a 20 lb bond paper, sourced assheets measuring 11-inches long and 14-inches wide. However, an array ofpaper products, available in various weights and provided as continuousrolls or sheets of various sizes, may serve as the paper substrate 16.Furthermore, the paper substrate 16 material may be chosen from avariety of natural and synthetic materials known within the art,including without limitation, paper, vinyl, plastic films or foils,fabrics, and textiles.

The label 10 may also include a layer of adhesive 18 affixing a firstlayer of lamination material 20 to a bottom surface of the papersubstrate 16. According to one embodiment, the first layer of laminationmaterial 20 comprises a layer of polypropylene or polyester film.However, the first layer of lamination material 20 may be chosen from avariety of lamination materials such as polypropylene films include“410” sourced from ACPO, Ltd. and “812C film” sourced from QSPACIndustries, Inc., and an exemplary polyester film is “609” sourced fromACPO, Ltd. These products are clear films that include the layer ofadhesive 18 already applied on one surface. Thus, when one of theseproducts is selected for use as the first layer of lamination material20, affixing the first layer of lamination material 20 involves applyingthe polypropylene or polyester film to the bottom surface of the papersubstrate 16 using the pre-applied adhesive 18. Polypropylene andpolyester films provide the advantage of allowing an adhesive strip 22to permanently adhere to a bottom surface of the first layer oflamination material 20. Thus, the adhesive strip 22 may stay entirely onthe bottom surface of a label 10 when it is peeled from a pad of labels12, with little to no adhesive residue left behind on the top surface ofthe label 10 directly below.

A first portion 10 a of the label 10 may be affixed to an article suchas a shelf, while a second portion 10 b of the label 10 may hangs belowthe shelf (see FIG. 1). A relief perforation 28 may extend between thefirst portion 10 a from the second portion 10 b to allow the secondportion 10 b to be removed from the first portion 10 a. Thus, theadhesive strip 22 may be applied to the bottom surface of the firstlayer of lamination material 20 only in an area corresponding to thefirst portion 10 a of the label 10, which is to be affixed to the shelf.In one embodiment, a top edge of the adhesive strip 22 is applied at adistance (D1) approximately ⅛ of an inch from a top edge of the label10. The distance D1 may vary approximately +/− 1/16 of an inch. Theadhesive strip 22 may have a height L2 ranging from approximately ⅝ ofan inch to approximately 1 inch, and its width may continue for the fullwidth of the label 10.

In one embodiment, the adhesive strip 22 is a double-coated tapecomprising a layer of polyester film 24 having layers of adhesive 26 a,26 b pre-applied on top and bottom surfaces thereof. However, theadhesive strip 22 may be chosen from a variety of materials includingwithout limitation, pattern-coated adhesives or double-coated tapesutilizing various substrate materials, such as paper, vinyl, plasticfilms or foils (including polyester and polypropylene), fabrics, andtextiles.

Examples of adhesive strips 120 include “FT 8380” and “FT 9380” productssourced from Avery Denison Corporation. These products are double-coatedpolyester tapes available in various widths, but commonly sourced inwidths ranging from ⅝ inch to 1 inch, and designed for cleanremovability. Both of these products may include a release liner 30installed on the outer facing adhesive surface. The release liner 30 maybe removed from the adhesive surface during the manufacturing process asdiscussed below. FT 8380 and FT 9380 are standard adhesive strips 120that have proven reliable for adhering labels 10 to store shelves, whilestill allowing for any necessary repositioning. The FT 9380 product is amore aggressive adhesive strip 22, suitable for use in applicationswhere label adhesion may present challenges.

In one embodiment, a layer of adhesive 32 affixes a second layer oflamination material 34 to a top surface of the paper substrate 16. Inone embodiment, the second layer of lamination material 34 comprises alayer of polyester film. However, the second layer of laminationmaterial 34 may be chosen from a variety of lamination materials knownin the art. The label 10 may further incorporate a release coating 36 ona top surface of the second layer of lamination material 34. In oneembodiment, the release coating 36 comprises a silicone coating, whichcovers the entire top surface of the second layer of lamination material34. The release coating 36 may allow each label 10 to function as therelease liner 30 for the label 10 directly above it once the releaseliner 30 has been removed and the labels 10 are stacked on top of oneanother. That is, the release coating 36 may allow the adhesive strip 22permanently affixed to the bottom surface of one label 10 to be cleanlyand easily peeled from the top surface of the label 10 directly beneathit in a pad 12, without any risk of tearing the labels 10 or leaving asubstantially about if any adhesive residue behind.

An exemplary polyester film that, according to the depicted embodiment,may be selected for use as the second layer of lamination material 34includes “Hostaphan 2 SLKN” sourced from Mitsubishi Polyester Film, Inc.This product is a clear polyester film, available in multiplethicknesses and commonly sourced in 92 and 102 gauge thicknesses.Hostaphan 2 SLKN comes pre-coated on one surface with a silicone releasecoating 36. Thus, when Hostaphan 2 SLKN is selected for use as thesecond layer of lamination material 34, adhesive 32 may be applied tothe film's surface opposite the silicone release coating 36.Alternatively, the adhesive 32 may be applied to the top surface of thepaper substrate 16. The Hostaphan 2 SLKN may then be applied to the topsurface of the paper substrate 16 using the adhesive 18. There may be noneed to apply a release coating 36 because Hostaphan 2 SKLN comes with asilicone release coating 36 pre-applied. Additional embodiments of thelabel 10 and pad 12 may be found in U.S. Patent Application PublicationNo. 2014/0367017 which is hereby incorporated by reference in itsentirety.

Referring to FIGS. 3 and 4, multiple labels 10 may be stacked into a pad12 such that each individual label 10 may be peeled from the pad 12 andused directly, such as attached to a store shelf. Thus, the pad 12 mayeliminate dozens of hours that store personnel traditionally spend eachweek breaking down sheets of labels by tearing along the label-removalperforations, sorting the individual labels, and containerizing orbundling the individual labels before installation.

The pad of labels 12 may provide further time savings and wasteminimization by eliminating the release liner 22 from the individuallabels 10. In one embodiment, using a label 10 requires removing a label10 from the pad of labels 12 and affixing it to an article such as astore shelf using the exposed adhesive strip 24. Because the individuallabels 10 in the pad 12 adhere to one another without any intermediaterelease liner 30, the labels 10 may be referred to as “peel-and-stick.”Thus, embodiments of the present invention may eliminate the need forstore personnel to peel away and discard a separate release liner 30before installing a label 10.

Further, the pad of labels 12 may be sequenced according to a store'splanogram. That is, the labels 10 may be arranged within the pad 12 andthe pads 12 may be arranged relative to one another by taking intoaccount the store's planogram, such that store personnel tasked withinstalling the labels 10 need only walk down a store aisle, peel thelabels 10 from the pad 12, and affix them to the store shelves as theyproceed down the aisle.

Referring to FIGS. 3 and 4, though a single pad 12 may be provided bystacking single labels 10 on top of one other, in some embodiments aplurality of pads 12 may be partially connected by stacking sheets ofpartially connected labels 100. The pads 12 may be partially connectedto one another so that a single pad of labels 12 can be easily detachedfrom the remaining pads 12. A plurality of pads 12 may be provided, insome embodiments, where the store is large and/or to further organizethe labels 10. For example, each shelf or aisle in a store may beprovided as a separate pad of labels 12. Each collection of pads 40 mayinclude any number of pads 12. The pads 12 may be arranged into a matrixarray having rows and columns of pads 12. In one embodiment, eachcollection of pads 40 includes 15 pads 12 arranged into five columns andthree rows. In one embodiment, the number of pads 40 is the maximumnumber of pads 40 that can be produced from a sheet that isapproximately 11 inches wide by approximately 13 and ⅞ inches long. Inone embodiment, the plurality of pads 12 are provided on top of a boardor backer 38 to form a set or collection of pads 40. In one embodiment,the backer 38 is an 8 point coated-one-side cardstock material that hasa release laminate applied to a top surface. The backer 38 may extendhorizontally further than the pads 12 along at least one edge of thepads 12. In one embodiment, the backer 38 extends horizontally furtherthan the pads 12 in order for a user to more easily grasp the backer 38while removing a pad 12 from the backer 38.

The backer 38 may be provided to help keep the pads 12 joined to oneanother and help to provide stiffness to the plurality of pads 12. Inone embodiment, the backer 38 includes a release coating similar torelease coating 36 and each pad 12 is coupled to the top surface of thebacker 38 by the exposed adhesive strip 22 of the bottom-most label 10.The backer 38 may include printed data, including without limitation,the store for which the labels 10 are intended and the location orlocations within the store where the labels 10 are to be installed.

Each pad 12 may be coupled to one another by one or more connections orties 42 between adjacent labels. In one embodiment, the ties 42 areformed by not cutting along an entire length of the boundary betweenlabels 10 during the cutting process, as described in further detailbelow. In one embodiment, two adjacent labels 10 are connected to oneanother by two ties 42. Fewer or additional ties 42 to couple adjacentlabels 10 may be used. In one embodiment, each tie 42 is less thanapproximately 0.03 inches wide in a direction parallel to the connectededges of the labels 10. In one embodiment, each tie 42 is approximately0.02 inches wide in a direction parallel to the connected edges of thelabels 10. In one embodiment, each tie 42 closest to the perimeter ofthe sheet of labels 100 is approximately 0.02 inches wide in a directionparallel to the connected edges of the labels 10 and each of the otherties 42 is approximately 0.025 inches wide in a direction parallel tothe connected edges of the labels 10. Having a tie that is greater than0.03 inches wide in a direction parallel to the connected edges of thelabels 10 may become difficult to tear, especially with taller pads 12.A pad of labels 12 may be released from the backer 38 by grasping thepad 12 and pulling upwardly and outwardly from the remaining pads untileach of the ties 42 are torn.

Each sheet of labels 100 may be aligned with the immediately underliningsheet of labels 10 during stacking of the sheets of labels 10. Becauseof the exposed adhesive strips 22 and the ties 42 connectinghorizontally adjacent labels, picking up each sheet and placing intoproper alignment with a stack of sheets as described in further detailbelow may result in a more precisely aligned pad of labels as comparedto a pad 12 formed by simply feeding the sheet of labels 10 into astack.

In one embodiment, each of the outer perimeters of the sheets of labelsare vertically aligned with one another. In one embodiment, each of theouter perimeters of the sheets of labels are vertically aligned with oneanother without having to trim the pads of labels after they arestacked. In one embodiment, each of the outer perimeters of the sheetsof labels are stacked on top of one another to be within+/−approximately 1/32 of an inch from a vertical reference lineextending perpendicular from the backer 38.

The method of making a pad of labels may include providing a substratehaving printed display material on a top surface of the substrate, afirst layer of lamination material on a bottom surface of the substrate,a second layer of lamination material having a release coating on thetop surface of the substrate, and an adhesive strip on the bottomsurface of the first layer of lamination material, the adhesive stripbeing covered by a liner material in accordance with the embodimentsdisclosed above. The method may include cutting the substrate into atleast one label. In one embodiment, cutting the substrate includescutting through the substrate and the first and second layer oflamination material around an entire outer perimeter of a plurality ofpartially connected labels. In one embodiment, cutting the substrateincludes cutting through the substrate along a majority of a boundarybetween adjacent labels leaving one or more ties to partially connectadjacent labels. In one embodiment, cutting the substrate includesleaving the liner material at least partially intact. In one embodiment,the substrate cutting process is performed using a rotary die.

The method may include removing the liner material to expose theadhesive strip after cutting the substrate into at least one label. Themethod may include pulling the at least partially intact linerdownwardly from the at least one labels and winding the at leastpartially intact liner onto a spool. The method may include pulling atrim surrounding the entire outer perimeter of the plurality ofpartially connected labels upwardly from the plurality of partiallyconnected labels and winding the trim onto a spool.

The method may include arranging the labels into a pad of labels. In oneembodiment, the labels are arranged by transporting the at least onelabel to a stacking station using a transfer conveyor having non-stickcoated rollers. In one embodiment, the labels are arranged bytransporting the at least one label which includes using a robot armhaving a vacuum pick-head to lift the at least one label and place theat least one label onto the top of the pad of labels. In one embodiment,air is blown onto the at least one label during transporting of the atleast one label to the stacking station. Additional methods and methodsteps are disclosed below in reference to uses of the exemplarymachinery.

Referring to FIGS. 5-14, a label assembly and stacking machine 44 may beprovided for assembling, cutting and stacking the labels 10 into pads12. In one embodiment, the label assembly and stacking machine 44includes a plurality of stations such as a feeding station 46, alaminating station 48, a die cutting station 50, a first unwindingstation 52, a second unwinding station 54, a conveyor station 56 and astacking station 58. Each of the stations may be coupled to one anotherin a single location similar to the machine 44 as illustrated in FIG. 5to provide a continuous processing of the labels. In one embodiment, themachine 44 automatically assembles, cuts and stacks the labels 10 intopads 12 without the need for human assistance or interaction during theprocess. The machine 44 may include wheels 60 such that the machine 44may be moved, either as a whole, or to split apart the various stationsfrom one another, such as for allowing for repairs. In otherembodiments, one or more of the stations is provided remotely orseparately from the other stations and an intermediate step, such asshipping the partially processed labels to another location for furtherprocessing, may be desired or required.

Referring to FIG. 6, an exemplary feeding station 46 is shown. Anothermachine or a user may load a stack of sheets of paper substrate 16 intoa bottom-fed friction feeder 60. A number of feeding mechanisms known inthe art may be used in accordance with the present invention to feedsubstrate material 16 into the laminating station 48 (FIG. 7), includingwithout limitation, bottom-fed and top-fed friction feeders. The sheetof paper substrate 16 may have preprinted on its top surface displayinformation as discussed above, which may include, without limitation,product information, descriptions, marketing content, store and shelflocation, pricing, discounts and promotions, UPCs and bar codes, andeffective dates. In other embodiments, paper substrate 16 is provided ona continuous roll.

The bottom-fed friction feeder 60 may feed the sheet of paper substrate16 onto a belt 62, which may carry the sheet of paper substrate 16 alonga table 64. The table 64 may include adjustable guides 66 to orient thesheet of paper substrate 16. The table 64 may also include one or moresensors 68 that detect the location of the leading edge of the sheet ofpaper substrate 16 over time. The laminator 70 may adjust the speed ofthe transport so that the sheet of paper substrate 16 has properregistration as it enters the lamination web.

FIG. 7 shows an exemplary lamination station 48. The sheet of papersubstrate 16 may enter the laminator 70 and then a first nip rollerstation 72 where it becomes part of a continuous roll, or web, ofmaterial 72. The sheet of paper substrate 16 may join a roll ofpolypropylene film, which serves as the first layer of laminationmaterial 20 on the bottom surface of the paper substrate 16. The roll ofpolypropylene film may be fed from a first laminate station 74. Thepolypropylene film 20 may be affixed to the bottom surface of the papersubstrate 16 through use of an adhesive 18. As previously described, thepolypropylene film may allow an adhesive strip 22 to permanently adhereto the bottom surface of the first layer of lamination material 20.Thus, the adhesive strip 22 may stay entirely on the bottom surface of alabel 10 when it is peeled from a pad of labels 12, and little to noadhesive residue is left behind on the top surface of the label 10directly below.

Additionally, the sheet of paper substrate 16 may join a roll ofpolyester film, which serves as the second layer of lamination material34 on the top surface of the paper substrate 16. The roll of polyesterfilm may be fed from a second laminate station 76. The polyester filmmay be affixed to the top surface of the paper substrate 16 through useof an adhesive 34. The polyester film forming the second layer oflamination material may incorporate a release coating 36 on its topsurface. As previously described, the release coating 36 may allow theadhesive strip 22 on the bottom surface of one label 10 to be cleanlyand easily peeled from the top surface of the label 10 directly beneathit, without any risk of tearing the labels 10 or leaving adhesiveresidue behind. Accordingly, the sheet of paper substrate 16 issuspended in a web of material 78 created by continuous rolls oflamination material.

The web of material 78 may next travel through a web tensioning station80 that ensures that proper and consistent tension is maintained in theweb 78 throughout the process. A web control guide 82 may sense the edgeof the web of material 78 and pivot in order to eliminate any skewingand to ensure that the sheet of paper substrate 16 suspended within theweb of material 78 enters the die station in the proper orientation,e.g. with the leading edge parallel to an axis of the die roller.

If the web of material 78 does not already include the adhesive strips22, the adhesive strips 22 are coupled to the bottom surface. Asdiscussed above, the adhesive strips 22 may include a release liner 30.The release liner 30 may prevent the adhesive strip 22 from sticking tothe machinery 44 and/or leaving a sticky residue on any of the machineparts.

FIG. 8 shows an exemplary die cutting station 50. The die cuttingstation 50 includes a die 86. The die 86 may include one or more bladesfor cutting the web of material 78 into a plurality of labels 10. In oneembodiment, the die 86 includes a matrix of blades for trimming,cutting, and perforating the web of material 78 to produce a particularsize and configuration of labels 100. The die cutting station 50 mayinclude one or more pairs of tensioning rollers 84 to tension andposition the web of material 78 before the web of material 78 is fedinto die 86. The die 86 may be coated with a foam layer 86 a extendingbetween the blades for providing pressure on the surface of the web ofmaterial 78 and controlling static as the web of material 78 passesthrough the die 86. In one embodiment, the foam layer 86 a is comprisedof an anti-static foam. In one embodiment the foam layer 86 a isapproximately 1/16 of an inch thick.

Referring to FIGS. 9A-9C, a first blade 88 may be used to make cuts thatextend entirely through the web of material 78, such as around theperimeter and between adjacent labels. A second blade 90, such as aserrated blade, may be used to make perforated cuts such as reliefperforations 28 (see FIG. 1). The first blade 88 may include gaps 88 afor creating the ties 42 (see FIG. 2) discussed above. In oneembodiment, the gaps 88 a are approximately 0.02 inches wide. In oneembodiment, the gaps 88 a are smaller proximate the perimeter (e.g.,approximately 0.02 inches wide) and larger toward the interior (e.g.approximately 0.025 inches wide) of the pattern. The first blade 88 mayinclude a reduced height section 88 b to only partially cut throughcertain layers of the web of material 78 also referred to as a kiss cut.In one embodiment, the reduced height section cuts through all layers ofthe web of material except for the release liner 30. The kiss cuts mayhelp to keep the release liners 30 attached to one another andstreamline removal of the release liner 30. In one embodiment, the firstblade 88 has a height of approximately 0.4 inches. In one embodiment,the reduced height section 88 b has a recess (i.e. a clearance) ofapproximately 0.0024 inches from the top of the first blade 88. FIG. 10illustrates an exemplary pattern of the die 86 in 2D.

After the web of material 78 has been cut into a sheet 100 of partiallyconnected labels 10 by die 86, the perimeter trimmings and the releaseliner may be removed. In one embodiment, the perimeter trimmings 92 areremoved from the labels 10 upwardly and the release liner 30 is removedfrom the labels 10 downwardly.

Referring to FIG. 11, an exemplary first unwinding station 52 is shown.The first unwinding station 52 may gather and unwind the release liner30 from the adhesive strips 22. The release liner 30 may be rewound ontoone or more mandrels 94 to collect the release liner 30. Once fullywound, the mandrels 94 may be discarded or the release liners 30 may bereused. Once exposed, the adhesive strips 22 will not come in contactwith any part of the label assembling and stacking machine 44 throughoutthe remaining steps in the manufacturing process, except for thetransfer rollers 98. Also shown in FIG. 11 is the roll 114 of bottomlaminate material 20 and the roll 116 of adhesive strips 22.

Referring to FIG. 12, an exemplary second unwinding station 54 is shown.The second unwinding station 54 may gather and unwind excess firstlamination material 20, second lamination material 34, and papersubstrate 16 (collectively, trim 92) that is trimmed away. The trim 92may include the web of material 78 that surrounds the sheet of labels100. In one embodiment, the trim 92 is in the shape of a continuousladder (see FIGS. 5 and 8). The trim 92 may be rewound onto one or moremandrels 96 to collect the trim 92. Once fully wound, the mandrels 96may be discarded. The sheet of partially connected labels 100 is nowready for stacking. By keeping the release liner 30 on through thecutting process, both the adhesive strips 22 and the die 86 areprotected during processing of the web of material 78.

Referring to FIG. 13, an exemplary conveyor station 56 is shown. Theconveyor station 56 may include a plurality of rollers 98 that transferthe sheet of labels 10 from the die cutting station 50 to the stackingstation 58 (FIG. 14). In one embodiment the rollers 98 are coated with anon-stick coating, such as a rubberized non-stick plasma coating, suchthat the exposed adhesive strips 22 do not adhere to the rollers 98. Theconveyor station 56 may include one or more hold down tabs 162 that helpto insure that the sheets of labels 100 stay in contact with the rollers98 during transport. In alternative embodiments, the conveyor station 56may be shortened or omitted.

In another embodiment, a moveable platform transfers the sheet of labels100 from the die cutting station 50 to the stacking station 58. Inanother embodiment, the sheet of labels 100 is transferred directly fromthe die cutting station 50 to the stacking station 58.

Referring to FIGS. 14 and 15, an exemplary stacking station 58 is shown.The stacking station 58 may include a transfer bin 102 for receiving thesheet of labels 100 from the conveyor station rollers 98. The transferbin 102 may include one or more guides 104 at an end of the transfer bin102 to engage the leading edge of the sheet of labels 100 and direct thesheet of labels 100 into the transfer bin 102. In one embodiment, theguides 104 comprise a plurality of padded posts. Additional guides 104may be provided around the lateral sides of the transfer bin 102. Thetransfer bin 102 may include one or more grooves or recesses 102 a. Thegrooves or recesses 102 a may be sized and oriented to align with theadhesive strips 22 of the sheet of labels 100 such that the adhesivestrips 22 do not contact the transfer bin 102. The stacking station 58may include one or more air nozzles 106 adjacent to the stacking stationto blow air on the sheet of labels 100 and help keep the sheet of labels100 on the rollers 98 and/or direct the sheet of labels 100 into thetransfer bin 102.

Because the sheet of labels 100 is flexible and includes a plurality ofapertures (e.g., the cuts between adjacent labels and the perforations)and the bottom surface includes exposed adhesive strips 22, it may bedifficult to accurately place the sheet of labels 100 into a precisestack or collection of pads 40. Once the sheet of labels 100 ispositioned in the transfer bin 102, a robot arm 108 may be used to pickup the sheet of labels 100 and accurately place the sheet of labels 100onto a stack or collection of pads 40.

The robot arm 108 may include one or more struts 108 a to precisely movea pick-head or plate 110. In one embodiment, the robot arm 108 includessix struts 108 a. The robot arm 108 may have at least one vacuum sourceconfigured to selectively supply a vacuum force to the sheet of labels100. The vacuum source may be provided by one or more conduits 112, suchas tubes, configured to pull and release a vacuum through the plate 110.In one embodiment, the vacuum force is approximately 10 psi. In oneembodiment, the vacuum force is approximately 9 psi to approximately 11psi. In one embodiment, the vacuum force is at least approximately 9psi. In one embodiment, the vacuum force is less than approximately 11psi.

The plate 110 may include a resilient or flexible pad 112. In oneembodiment, the flexible pad 112 is provided to protect the labels 10from being damaged by plate 110. In one embodiment, the flexible pad 112is comprised of foam. The flexible pad 112 may be comprised of two ormore layers having different durometers. In one embodiment, the foamincludes a top layer of closed cell foam 112 b and a bottom layer ofopen cell foam 112 c. In one embodiment, the bottom layer of foam 112 cprovides greater conformity to the perforations and cuts in the sheet oflabels 100 while the top layer of foam 112 b allows for greater vacuumgeneration. In one embodiment, the top layer of foam 112 b is a closedcell, medium density, polyurethane foam. In one embodiment, the toplayer of foam is approximately ⅜ of an inch thick. In one embodiment,the bottom layer of foam 112 c is an open cell, low density foam. In oneembodiment, the bottom layer of foam is approximately ⅙ of an inchthick.

In one embodiment, the plate 110 and the flexible pad 112 are generallythe same size and shape. In one embodiment, the plate 110 and theflexible pad 112 are generally rectangular. In other embodiments, theplate 110 and the flexible pad 112 are any shape include round, oval,triangular and square. In one embodiment, the plate 110 and the flexiblepad 112 are generally the same size and shape as the sheet of labels100. In one embodiment, the plate 110 and the flexible pad 112 aresmaller than the sheet of labels 100.

The flexible pad 112 may include a plurality of apertures 112 aextending through the flexible pad 112 and configured to direct themajority of the vacuum force through the flexible pad 112 and to thesurface of the sheet of labels 100. The apertures 112 a may beapproximately 5 mm in diameter and approximately ¾ inch apart fromcenter to center. In one embodiment, the apertures 112 a are arranged inan array of aligned rows and columns. In other embodiments, theapertures 112 a are arranged in rows that are offset from adjacent rows.In other embodiments, the apertures 112 a are sized, spaced and arrangeddepending on the label size and layout of the sheet of labels 100. Inone embodiment, the apertures 112 a are positioned so that they do notsubstantially intersect a cut or perforation in the sheet of labels 100.In one embodiment, even if some of the apertures 112 a intersect with acut or perforation in the sheet of labels 100, there are a sufficientnumber of apertures 112 a that do not intersect with a cut orperforation in the sheet of labels 100 allowing for the vacuum force tohold the sheet of labels 100 in contact with the flexible pad 112.

Once a sheet of labels 100 is in the transfer bin 102, the robot arm 108may come down over top of the sheet of labels 100 and contact the bottomof the flexible pad 112 to the top surface of the sheet of labels 100. Avacuum force may be drawn through the plurality of apertures 112 a tohold the sheet of labels 100 onto the flexible pad 112. The robot arm108 may then be lifted to pick up the sheet of labels 100 and positionthe sheet of labels 100 onto the top of and in aligned with thecollection of pads 40. In one embodiment, the vacuum force iscontinuously drawn through the flexible pad 112 to retain the sheet oflabels 100 until the sheet of labels 100 is stacked into place. Oncestacked, the adhesive strip 22 on the bottom surface of each label 10adheres to the top surface of the label 10 below it, resulting in a pad12 of peel-and-stick labels 10. The vacuum force drawn through theflexible pad 112 may then be released and the robot arm 108 returnstoward the transfer bin 102 to pick up another sheet of labels 100. Thisprocess may be repeated until a desired number of sheets of labels 100are stacked. The robot arm 108 may be controlled by a computer that ispre-programmed to automatically pick up and place the sheet of labels100 in a quick and precise manner.

The printing, cutting, and stacking processes described above anddepicted in FIG. 5-14 may be controlled by taking into account thestore's planogram, such that the finished pad of labels 12, 40 aresequenced according to the store's planogram. Thus, the store personneltasked with installing the labels 10 need only walk down a store aisle,peeling the labels 10 from the pad 12, and affixing them to the storeshelves.

In one embodiment, the system includes one or more computers having oneor more processors and memory (e.g., one or more nonvolatile storagedevices). In some embodiments, memory or computer readable storagemedium of memory stores programs, modules and data structures, or asubset thereof for a processor to control and run the various systemsand methods disclosed herein. In one embodiment, a non-transitorycomputer readable storage medium having stored thereoncomputer-executable instructions which, when executed by a processor,perform one or more of the methods disclosed herein.

It will be appreciated by those skilled in the art that changes could bemade to the exemplary embodiments shown and described above withoutdeparting from the broad inventive concepts thereof. It is understood,therefore, that this invention is not limited to the exemplaryembodiments shown and described, but it is intended to covermodifications within the spirit and scope of the present invention asdefined by the claims. For example, specific features of the exemplaryembodiments may or may not be part of the claimed invention and variousfeatures of the disclosed embodiments may be combined. Unlessspecifically set forth herein, the terms “a,” “an” and “the” are notlimited to one element but instead should be read as meaning “at leastone.”

It is to be understood that at least some of the figures anddescriptions of the invention have been simplified to focus on elementsthat are relevant for a clear understanding of the invention, whileeliminating, for purposes of clarity, other elements that those ofordinary skill in the art will appreciate may also comprise a portion ofthe invention. However, because such elements are well known in the art,and because they do not necessarily facilitate a better understanding ofthe invention, a description of such elements is not provided herein.

Further, to the extent that the methods of the present invention do notrely on the particular order of steps set forth herein, the particularorder of the steps should not be construed as limitation on the claims.Any claims directed to the methods of the present invention should notbe limited to the performance of their steps in the order written, andone skilled in the art can readily appreciate that the steps may bevaried and still remain within the spirit and scope of the presentinvention.

We claim:
 1. A method of making a pad of labels comprising: providing asubstrate having printed display material on a top surface of thesubstrate, a first layer of lamination material on a bottom surface ofthe substrate, a second layer of lamination material having a releasecoating on the top surface of the substrate, and an adhesive strip onthe bottom surface of the substrate; cutting the substrate into at leastone label; and arranging the at least one label into a pad of labels,wherein the providing, cutting, and arranging steps are controlled withreference to a store's planogram, such that the pad of labels issequenced according to the store's planogram.
 2. The method of claim 1,wherein the at least one label include a sheet of labels, and whereinthe cutting step includes cutting through the substrate and the firstand second layer of lamination material around an entire outer perimeterof a plurality of partially connected labels.
 3. The method of claim 2,wherein the cutting step includes cutting through the substrate along amajority of a boundary between adjacent labels leaving one or more tiesto partially connect adjacent labels.
 4. The method of claim 3, whereinthe cutting step includes partially cutting the at least one labelproximate the adhesive strip.
 5. The method of claim 4, wherein theadhesive strip is covered by a liner material, and wherein partiallycutting the at least one label proximate the adhesive strip is done suchthat the liner material is at least partially intact across the sheet oflabels, the method further comprising: removing the liner material toexpose the adhesive strip after cutting the substrate into at least onelabel; and pulling the at least partially intact liner downwardly fromthe at least one labels and winding the at least partially intact lineronto a spool.
 6. The method of claim 4 further comprising: pulling atrim surrounding the entire outer perimeter of the plurality ofpartially connected labels upwardly from the plurality of partiallyconnected labels and winding the trim onto a spool.
 7. The method ofclaim 1, wherein the cutting step is performed using a rotary die. 8.The method of claim 7, wherein the rotary die includes a plurality ofcutting edges, at least one of the plurality of cutting edges extendingradially further from the rotary die than another one of the pluralityof cutting edges.
 9. The method of claim 1 further comprising:transporting the at least one label to a stacking station using atransfer conveyor having non-stick coated rollers.
 10. The method ofclaim 9, wherein transporting the at least one label includes using arobot arm having a vacuum pick-head to lift the at least one label andplace the at least one label onto a top of the pad of labels.
 11. Themethod of claim 1 further comprising: printing the display material onthe top surface of the substrate; affixing the first layer of laminationmaterial to the bottom surface of the substrate; affixing the secondlayer of lamination material to the top surface of the substrate; andapplying the adhesive strip to the bottom surface of the first layer oflamination material.
 12. The method of claim 1, wherein the adhesivestrip is covered by a liner material, the method further comprising:removing the liner material to expose the adhesive strip after cuttingthe substrate into at least one label.
 13. The method of claim 10,wherein the pick-head includes a foam pad.
 14. The method of claim 13,wherein the foam pad includes a plurality of apertures.
 15. The methodof claim 14, wherein the apertures are approximately 5 mm in diameter.16. The method of claim 10, wherein the vacuum force is approximately 10psi.